Apparatus for securing and covering a clamping device for solar panel modules

ABSTRACT

The present invention is directed to a covering for a clamping assembly used to connect and ground solar panel modules to a mounting rail. The covering comprises a sleeve including an outer cover for connecting to the solar panel module and a connector shaped to be contained within the outer cover and connected to the outer cover through two or more flanges. The connector has an opening there through to receive a female member of the clamping assembly.

FIELD OF THE INVENTION

The present invention relates generally to an apparatus for securing andcovering a clamping assembly used to connect and ground multiple objectstogether. In particular, the clamping assembly is similar to theassemblies that have been disclosed in U.S. Publication 2015/0311606(“the '606 Publication”) that clamp and electrically bonds a solar panelmodule to a solar panel mounting rail. More specifically, the inventionis a sleeve that fits and snaps onto the clamping assembly and enablesthe assembly to serve as an end clamp in the solar panel array.

BACKGROUND OF INVENTION

The installation of solar panel arrays on residential roofs can bearduous and time-consuming. Depending on the array design, thecomponents required to install the array can make the installationprocess even more difficult. Many of the assembly components requirespecial tools or are generally difficult to install because they areutilized after the solar panels modules are arranged or positioned ontheir support elements. This is particularly true when the elements mustbe installed on a roof that links to a rail guide for supporting thesolar panel array.

In a typical support rail guide system, solar panel modules are arrangedacross the top of several rail guides. This may occur, for example, byusing mounting clamps that secure solar panel modules along the top ofthe rail guide. The rail guides in turn are supported to a roof byflashings.

The clamping devices, like those disclosed in the '606 Publication,which this application incorporates by reference, are examples ofclamping assemblies used to secure a solar panel module to the top of arail guide. These clamping assemblies are typically installed as amid-clamp within the solar panel array. When positioned along the lowerend of the solar panel array, the clamp assembly is exposed and can havean unsightly appearance. The present invention provides a sleeve thatfits and snaps onto the clamp assembly and covers the assembly so thatthe assembly can be used as an end clamp without exposing the parts ofthe assembly on the lower end of the array. The present invention isalso easy to install, use, and manufacture.

SUMMARY OF THE INVENTION

The invention is summarized below only for purposes of introducingembodiments of the invention. The ultimate scope of the invention is tobe limited only to the claims that follow the specification.

It is an object of this invention to provide an apparatus for covering aclamp assembly that is used to secure a solar panel module to a railguide structure.

It is a further object of this invention that the apparatus is a sleevethat fits on an elongated portion of the clamp.

It is a further object of this invention that the apparatus can snap onto the elongated portion of the clamp assembly.

It is a further object of this invention that the clamp provides a coverfor the clamp assembly that prevents exposure of the clamp to open view.

It is a further object of this invention that the elongated portion ofthe clamp assembly is the elongated portion described and illustrated inthe '606 Publication.

A person with ordinary skill in the relevant art would know that anyshape or size of the elements described below may be adopted. Anycombinations of suitable number, shape, and size of the elementsdescribed below may be used. Also, any materials suitable to achieve theobject of the current invention may be chosen as well.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete understanding of the present invention may be derived byreferring to the detailed description and claims when considered inconnection with the following illustrative figures. In the followingfigures, like reference numbers refer to similar elements and stepsthroughout the figures.

FIG. 1 illustrates a top perspective view of an exemplary clampassembly.

FIG. 2 illustrates a bottom perspective view of the clamp assembly shownin FIG. 1.

FIG. 3 illustrates a rear perspective view of an exemplary clampassembly sleeve.

FIG. 4 illustrates a front perspective view of the clamp assembly sleevein FIG. 3.

FIG. 5 illustrates a perspective view of a pre-assembled combination ofthe clamp assembly sleeve and the clamp assembly as shown in FIGS. 1-4.

FIGS. 6A and 6B illustrate side and front perspective views of theassembled clamp assembly and clamp assembly sleeve.

FIG. 7 illustrates a front perspective view of a fully assembled clampassembly and clamp assembly sleeve in use while securing a solar panelmodule to a rail guide.

FIG. 8 illustrates a cross-section view of the assembled product shownin FIG. 7.

DETAILED DESCRIPTION OF THE INVENTION

In the following description, and for the purposes of explanation,numerous specific details are provided to thoroughly understand thevarious aspects of the invention. It will be understood, however, bythose skilled in the relevant arts, that the present invention may bepracticed without these specific details. In other instances, knownstructures and devices are shown or discussed more generally to avoidobscuring the invention. In many cases, a description of the operationis sufficient to enable one to implement the various forms of theinvention, particularly when the operation is to be implemented insoftware. It should be noted that there are many different andalternative configurations, devices and technologies to which thedisclosed embodiments may be applied. The full scope of the invention isnot limited to the example(s) that are described below.

FIGS. 1 and 2 show top and bottom perspective views respectively of anexemplary embodiment of a clamp assembly 100. The clamp assembly 100 isthe clamp described and disclosed in FIGS. 9-13 of the '606 Publication,although the present invention can also be used with a clamp assemblythat utilizes an elongated female member similar to that describedbelow. The clamping assembly 100 includes a male member 130 and anintegrated female member 140. The integrated female member 140 is alsoreferred to as a binding bolt and is typically cylindrically shaped.This exemplary clamp assembly in this embodiment is a rounded headmid-clamp clamping assembly 100 defines an integrated structure, suchthat all the elements of the female member are one piece. Together themembers 130 and 140 define a fastener that is used to fix solar panelmodules to a mounting rail/racking system.

The male and female members, 130 and 140 are interlocking. The malemember has an elongated male element defining a threaded shank 135 andan enlarged end defining a T-bolt end 110. The T-bolt end 110 includesat least one raised portion 120 that is designed for penetrating thesurface treatment layer of the solar panel mounting rails and may alsoinclude a roller 180. In the embodiment shown, there are a plurality ofraised portions 125 defining teeth, which create a pre-determinedpattern. The pattern facilitates the penetration of the surfacetreatment layer of the rails by the male member 130 with only a pressurefit. Additionally, in the embodiment shown, the male member 130 iselectrically conductive and made from electrically conductive material.

Likewise, the entire female member 140 is also electrically conductive.The female member 140 defines an integrated member that includes a nutend 150, an annular ring 160 defining a piercing member 170. The nut end150 is not limited to a conventional hexagonal nut and can comprise anydrive type capable of advancing the female member 140 by hand or with atool such as a torx or allen drive. The female member 140 includes anelongated female element 145 that is generally cylindrical and extendsfrom the nut end 150. Each of the above elements are integrated as ifthey are a single unit with no movement with respect to one another, butalternatively the elongated female member 145 and the annular ring 160can be separate elements as long as the annular ring 160 is free to movealong the elongated female member 140.

The elongated male element 130 has defines the threaded shank 135. Theelongated female element 140 defines a sheath that is a cylindricalmember and has internal threads which are functionally compatible withthe external threads 135 (also shown in FIG. 10B of the '016application. Thus, the above-described structure provides an adjustableinterlocking fastener assembly for among other things mounting solarpanel frames on support rails.

The piercing member 170 includes washer with an annular ring 160 and acenter opening. The center opening is sized and shaped to allow theelongated female member 140 passage through the center opening.Additionally, the annular ring 160 has a raised portion for penetratinga metal frame as described above. The raised portion defines thepiercing member 170. The piercing member 170 has an edge sharp enough topierce the surface treatment layer of the solar panel mounting rail asbest seen in FIG. 7.

As shown in FIG. 7, the rounded head mid-clamp 100 is used to affix asolar panel frame 400 to a mounting rail 300. The rounded head mid-clamp100 is typically used to clamp solar panel frames 400 side-by-side andthe mounting rail 300 that runs under and perpendicular to the frames400. The solar panel module includes a rear side 410 and a bottom 430.The male and female members, 130 and 140 respectively, are connected byloosely screwing the members together. The elongated portions 135 and145 of the male and female portions respectively, thereby form avertical member, which is vertically aligned with the channel 310 ofmounting rail 300. The mounting rail 300 also includes a hollow center320.

As illustrated, the T-bolt end 110 is adjustable and rotates withrespect to the female member 140. After alignment, the female member ispressed against the rear side 410 of the frame 400 with the penetratingmember 170 piercing the surface treatment layers of frame 400. TheT-bolt end 110 is turned so that it fits within the channel 310. Uponproper placement, so that the T-bolt end 110 fits squarely into thechannel, the nut end 150 is tightened. The nut end 150 is tighteneduntil raised portions or teeth 125 pierce the surface treatment layerinside the channel 310. The installer uses one hand to tighten the nutend 150, while the other hand is simply there to guide the fastener sothat assembly retains its proper positions. It will be understood thatsince the female member has already been affixed to the top panel 400 asillustrated, the rounded head mid-clamp 100 can in most instances beinstalled one-handed.

With particular reference to FIGS. 3 and 4, an exemplary sleeve 200 isshown. The sleeve 200 fits onto the clamp assembly 100 and serves as anend clamp for the clamping assembly 100. The sleeve 100 typically snapsinto place over the binding bolt 140 on the clamping assembly 100. Anexemplary embodiment of the sleeve 200 includes an outer cover 220 thatis typically semi-cylindrical, a connector 210 that is also generallysemi-cylindrically shaped, and a rear support 230. The diameter of theouter cover 220 is typically the same as the nut end 150 of the clampassembly 100, but it could be less if desired. The connector 210 isintegrated with the outer cover 220, and in an alternate embodiment, theouter cover 220 could serve as the connector 210 if it is desired thatthe outer cover 220 does not have to be the same or similar diameter tothat of the nut end 150 or annular ring 160 of the nut end 150. In FIGS.3 and 4, the connector 210 is joined by extensions perpendicularlycoupled to the outer cover 220, but it is understood that the connector210 could be fully integrated with the outer cover 220 as well. Theconnector 210 is typically made from a resilient material that and, asshown in FIG. 5, engages the binding bolt 140 by snapping in generallyperpendicular direction directly over it so that the binding bolt 140fits within a portion of the connector 210 until it contacts the rearsupport 230. The rear support 230 extends perpendicularly from the rearof the connector 210. The rear support 230 is optional, but in thepresent invention utilizes it for tactile feedback to notify theinstaller that the binding bolt 140 has been fully inserted.

FIGS. 6A and 6B show how the assembled sleeve 200 is connected to theclamp assembly 100. As shown, the sleeve 200 is pushed onto the bindingbolt 140 until it snaps securely into place within the connector 210 andreaches the rear support 230. FIG. 7 shows the sleeve 200 when it isconnected to the clamp assembly 100 and when the clamp assembly 100 hasbeen used to secure the solar panel module 400 to the mounting rail 300.When fully assembled, the sleeve 200 enables the clamp assembly to actas an end clamp that secures the solar panel module 400 to the mountingrail on the perimeter of the solar panel array and keeps the extendedmale and female members hidden from view as shown in FIGS. 6B and 7.

FIG. 8 shows a cross-sectional view of FIG. 7. The piercing member 170also penetrates the surface layer of the sleeve 200. By doing so, thesleeve 200 is electrically bonded to the clamp assembly 100, the solarpanel module 400, and the mounting rail 300.

What is claimed is:
 1. A clamping assembly comprising: a. a boltcomprising: i. an enlarged end comprising at least one serration on atop surface of the enlarged end configured to penetrate a surfacetreatment layer of a solar panel rail guide; ii. a cylindrical memberhaving a first end and a second end wherein the first end is coupled tothe top surface of the enlarged end so that the cylindrical member isperpendicular to the enlarged end; b. a nut comprising at least oneserration on a bottom side of the nut configured to penetrate a surfacetreatment layer of a support bracket and the nut being coupled to thesecond end of the cylindrical member through an opening on the bottomside; and c. the enlarged end is configured for: i. insertion in a firstorientation along a length of the solar panel rail guide; ii. rotationto a second orientation such that the enlarged end engages the railsupport guide; d. a semi-cylindrical sleeve having an upper end engagingthe bottom side of the nut and a lower end configured to engage thesolar panel rail guide, wherein the sleeve comprises: i. asemi-cylindrical outer cover having an open top, an open bottom and alongitudinally-extending sidewall opening extending between an outersurface and an inner surface thereof; and ii. a semi-cylindricalconnector concentrically disposed within the outer cover and radiallycoupled to the inner surface of the outer cover by a plurality offlanges, the connector comprising an open top, an open bottom and alongitudinally-extending sidewall opening extending between an outersurface and an inner surface thereof and aligned with the sidewallopening of the outer cover, the connector comprised of a resilientmaterial that is configured to snap onto, and secure the connectoraround a portion of the cylindrical member of the clamping assembly in adirection perpendicular to the cylindrical member.
 2. The assembly ofclaim 1 wherein the connector further comprises a rear support thatextends outward from the connector and contacts the cylindrical memberwhen the cylindrical member is coupled to the connector.
 3. The assemblyof claim 1 wherein the diameter of the outer cover is greater than thediameter of the cylindrical member and less than or equal to the widthof the nut.
 4. The assembly of claim 1 wherein the nut further comprisesa gripping structure on a top side of the nut.